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Pelican Technical Article:

Rear Door Panel Removal

Steve Vernon

Time:

1 hour1 hr

Tab:

$0

Talent:

*

Tools:

Phillips screwdriver, trim removal tool

Applicable Models:

Mercedes-Benz W124 (1986-95)

Hot Tip:

Door panels are expensive, take your time

Performance Gain:

Doors that work

Complementary Modification:

Replace switches

This article will show you how to remove your rear door panel. It is not a difficult job, but the door panels can be very expensive so take your time and double check things. Also, if you are going to be working on your own car, it is a good idea to purchase a set of trim removal tools. They are a set of hard yet flexible plastic tools of different shapes and sizes that are used in removing trim pieces. They work much better than a flathead screwdriver. There is nothing worse than ruining a "do-it-yourself" project by scratching up your car or damaging expensive interior pieces. Pelican sells a full line of these tool sets for under $20.

Before you begin removing the door panel, you should park the car on as level ground as possible. Nothing is more frustrating than working on the door while it is swinging.

Begin by opening the rear door and unscrewing and removing the plastic lock pull.
Figure 1

Begin by opening the rear door and unscrewing and removing the plastic lock pull.

Use a Philips head screwdriver and remove the single screw holding the trim piece from around the door latch.
Figure 2

Use a Philips head screwdriver and remove the single screw holding the trim piece from around the door latch. Remove the trim piece (red arrow).

Use a trim removal tool and pop the light from the lower door panel edge.
Figure 3

Use a trim removal tool and pop the light from the lower door panel edge. Disconnect the wiring (red arrow).

Use the trim removal tool and gently pry the switch and handle trim piece away from the door panel (red arrow).
Figure 4

Use the trim removal tool and gently pry the switch and handle trim piece away from the door panel (red arrow).

There are a series of clips holding the piece in place (red arrows) so use care not to break them.
Figure 5

There are a series of clips holding the piece in place (red arrows) so use care not to break them. You have to slide the housing towards the front of the car and it will then come out, hinging on the metal clip that is at the rear. With the trim piece removed unplug the window switch (yellow arrow).


NOTE: On the 1995 e300, one of the clips that is closest to the front of the car is a locking one that needs to be un-latched using a small flat screwdriver before it will let go. If you pry it, it may break.

Pull back the foam and remove the large screw with a Philips head screwdriver (red arrow).
Figure 6

Pull back the foam and remove the large screw with a Philips head screwdriver (red arrow).

There is a plastic retainer that the inner door pull attaches to.
Figure 7

There is a plastic retainer that the inner door pull attaches to. Pop this out from behind the door handle (red arrow). Push the door handle and plastic base towards the front of the vehicle. This will free the assembly from the door frame.

There are three plastic tabs (red arrow) that sit in cut outs in the doorframe (green arrow).
Figure 8

There are three plastic tabs (red arrow) that sit in cut outs in the doorframe (green arrow). The yellow arrow indicates the plastic retainer that the pull sits in.

Pull or lift the door panel up and out from the window rail (red arrows).
Figure 9

Pull or lift the door panel up and out from the window rail (red arrows).

Continue lifting the panel upwards until all nine of the plastic clips that hold the panel to the door are free.
Figure 10

Continue lifting the panel upwards until all nine of the plastic clips that hold the panel to the door are free. Disconnect the wiring connection for the speaker (red arrow).

This photo illustrates the interior of the door panel.
Figure 11

This photo illustrates the interior of the door panel. You can see the nine hooks that hold it to the door (red arrows).

With the door panel removed, you'll see the moisture barrier on the door.
Figure 12

With the door panel removed, you'll see the moisture barrier on the door. You'll want to carefully peel this off the inside of the door starting at the rear edge of the door. The idea is to peel it off in just a way so that it can be glued back onto the door later. Installation is the reverse of removal.


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Comments and Suggestions:
Alex Comments: I second Jack's comment on figure 5 - you have to slide the housing towards the front of the car and it will then come out, hinging on the metal clip that is at the rear.

Also, on figure 4 and 5 for my 1995 e300, one of the clips that is closest to the front of the car is a locking one that needs to be un-latched using a small flat screwdriver before it will let go. If you pry it, it may break.
September 16, 2016
  Followup from the Pelican Staff: Thanks for the additional info. We appreciate it. I will have the article updated.
- Nick at Pelican Parts
 
Jack Comments: Re Figure 5: My 1992 W124.128 has a metal clip at the rear of this cover. After popping the plastic clips at the top, bottom and front of the cover, you slide it off towards the front of the car.

Thanks for the article. Very helpful.
May 12, 2016
  Followup from the Pelican Staff: Thanks for sharing your installation process and experience. These type of comments add so much to the Pelican tech community.
- Nick at Pelican Parts
 

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